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SMALL TRACK MACHINES

SMALL TRACK MACHINES. Features. Mechanized maintenance of track was introduced in early sixties. Track machines are of two categories: Heavy track machines Small track machines. For Heavy track machines, Track Machine Manual was first published in March, 2000.

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SMALL TRACK MACHINES

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  1. SMALL TRACK MACHINES

  2. Features • Mechanized maintenance of track was introduced in early sixties. • Track machines are of two categories: • Heavy track machines • Small track machines. • For Heavy track machines, Track Machine Manual was first published in March, 2000. • For Small track machines (STM), Manual was first published in July, 2005.

  3. SMALL TRACK MACHINE-SETUP At HQ level - • Under the overall charge of CTE or CE/TM • Assisted by one Dy. Chief Engineer for small track machines. At Divisional level – Sectional Sr.DEN/DEN – procurement, maintenance Sectional ADEN & SSE/JE/P.Way – maintenance One SSE (P-Way) to be in charge of STM Depot in Sub-division.

  4. Need for STM • To fill working gap between heavy track machines & manual working. • Difficulty in maintenance of heavy track structure with conventional method. • To have compatible maintenance system between track machine maintenance. • To assist sectional gang with machines for travel, transport, handling of materials, lifting, levelling, lining & packing of track at isolated locations.

  5. Need for STM • Due to heavy axle load & increase in traffic density, frequent attention at isolated locations is needed in less available time & manpower. • Effective in restoration, accidents & unusuals. • Improves productivity, quality & safety of track operations. • Shortage of manpower/labour. Age factor of existing track men. • Change in attitude of working class towards hard manual labour.

  6. VARIOUS SMALL TRACK MACHINES • Machines For Operations on RAIL • Machines For Operations on Sleeper • Machines For WELDING OPERATIONS • Machines For Operation on Fittings • Machines For Lifting And Slewing of track • Machines For Track & Ballast

  7. MACHINES FOR OPERATIONS ON RAIL 1. Abrasive rail cutter. 2. Rail cutting machine (Saw type). 3. Rail drilling machine. 4. Chamfering kit. 5. Hydraulic rail tensor (Non-infringing type), 70t capacity. 6. Hydraulic rail bender ( Jim crow), heavy duty.

  8. Abrasive Rail Cutter

  9. Abrasive Rail Cutter Salient features: • Prime mover - A petrol engine of about 7 HP at 7000 RPM . • Fuel Tank Capacity - At least 1 litre, which shall be sufficient for at least 5 cuts in 52 kg, 90 UTS rails. • Overall weight - Maximum 35 kg. • Tolerance - + 1 mm both for vertical and lateral faces of railhead.

  10. Abrasive Rail Cutter • No. of cuts per disc- Minimum 7 cuts on 52 Kg, 90 UTS • Cutting time - (i) 60 Kg/m, 110 UTS -- 5 min (ii) 60 Kg/m, 90 UTS -- 4 min (iii) 52 Kg/m, 90 UTS & other rails -- 3 min (iv) 52 Kg/m, 72 UTS & other rails – 2 min • Man Power- 1 skilled person --- To operate the machine. 1 unskilled person --- To carry it.

  11. Rail Cutting Machine (Saw type)

  12. Rail Cutting Machine (Saw type) Salient Features: • Prime mover— Petrol start, kerosene/petrol run engine 2.0 to 3.0 HP capacity at 3000-4000 rpm. • Fuel tank capacity-- Sufficient for making 4 to 5 rail cuts. • Overall weight of the machine including wheel arrangement shall not exceed -- 70 Kg • Cutting time for each cut-- Maximum time is 30 minutes.

  13. Rail Cutting Machine (Saw type) • Tolerance of squareness both vertical and lateral -- +1.0 mm • Fuel consumption -- Minimum two cuts for 1 litre fuel. • Man Power -- Skilled --- 01 -- Unskilled --- 01 • The high speed steel of hacksaw blade should confirm to XT 87 W 6 Mo 5 Cr 4 V2 as per IS: 7291-1981. • The blades should be of ‘All hard (Type A) conforming to IS:2594:77 (Specifications for hacksaw blades).

  14. Rail Drilling Machine

  15. Rail drilling machine Salient Features: • Overall weight -- 65 Kg ( Approx.) • Drilling time -- 3 to 4 minutes • Fixing time -- 2 minutes • Prime Mover (Engine)- Petrol start, kerosene/petrol run 3 HP engine at 3000 to 4000 rpm. • Fuel tank capacity -- 2.0 Litres ( Approx)

  16. Rail drilling machine • Fuel consumption - Minimum 10 holes in 60Kg/90UTS rails with 1 liter of fuel. • No. of holes in a day - 60 holes (Approx.) • Tolerance for diameter and position of the hole - + 0.7 mm • Drill bit - As per I.S : 5103- 1969 and shall last for 100 fish bolt holes in 60 Kg/90 UTS rails. • Man Power - Skilled - 01 Unskilled - 01

  17. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type)

  18. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) Use: Hydraulic tensor is used for de-stressing of LWR track and for maintaining specified gap at rail joints. Man Power: Skilled : 01 Unskilled : 03

  19. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) • The main components of the machine :- (i) Rail gripping heads or yokes, (ii) Lever arm assembly, Right & Left hand (iii) Cylinders, (iv) Connecting rods, (v) Pins, (vi) Pump with tank.

  20. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) Salient features : • Maximum total weight including hand pump-- 375 Kg. • Maximum weight of any individual part -- 115 Kg • Maximum pulling force -- 70 t • Maximum pushing force -- 30 t • Hydraulic ram stroke -- 300 mm ( min.) • Rail section to be handled (To pull up to 150 mm) -- 90 R/52 Kg /60 Kg.

  21. Chamfering kit

  22. Chamfering kit Description Of Items: 1. H.T. Bolt, 2. H.T. Nut, 3. Chamfering Bit, 4. Packing Piece, 5. Torque Wrench. Note: The dimensions and assembling of different parts should be as per drawing no. TM/0512.

  23. Chamfering kit Use : Chamfering kit is a tool used for chamfering and work hardening the sharp edges of the periphery of the fish bolt hole to eliminate chances of developing crack at the sharp edges of the drilled holes. Man Power: Skilled : 01 Unskilled : 01

  24. Hydraulic Rail Bender (Jim Crow), Heavy duty Use:It Is used for bending/de-kinking of all types flat bottom rails in horizontal plane.

  25. Hydraulic Rail Bender ( Jim Crow), Heavy Duty Salient features : • Bending force : 60 tonnes • Maximum piston stroke : Not less than 40 mm, • Weight : Maximum 115 Kg, • Holding span for bending : 725-900 mm, • Time for operation : 10 minutes (Approx.) • Time for fixing : 2 minutes (Approx.) • Man Power : Skilled : 01 Unskilled : 01

  26. Machines For Operations On Sleeper 1. Hydraulic sleeper spacer, 2. Concrete sleeper breaker

  27. Hydraulic Sleeper Spacer Use:It is used for re-spacing/squaring of sleepers.

  28. Hydraulic Sleeper Spacer Salient features : • Weight (without operating lever and reaction rods) : 14 Kg ( maximum), • Rated capacity : 8 tonnes, • Length of hydraulic jack in closed position : 200 mm, • Hydraulic lift : 125 mm, (Travel of ram), • Screw extension : 75 mm (Minimum), • Time for squaring the sleeper : 5 –7 min., including fixing and removal, • Base size : 150 mm x 140 mm

  29. Hydraulic Sleeper Spacer Components: 1. Hydraulic Jack - Of 8 t capacity, 2. Back plate - With tapered thickness, 3. Saddle Cap, 4. Reaction rods. Man Power : Skilled : 01 Unskilled : 01

  30. Concrete sleeper breaker and angle grinder

  31. Concrete Sleeper Breaker And Angle Grinder Use: 1. It is used primarily for breaking the concrete sleepers into pieces thereby facilitating quick removal of damaged concrete sleepers and restoration of Railway Track in case of accidents/derailments and other emergent situations. 2. It can also be used for breaking brick work, asphalt and rocks.

  32. Concrete Sleeper Breaker And Angle Grinder Description: It is an electrically/ engine (Petrol or diesel) driven breaking equipment which imparts vibrational impacts through a drill bit/chisel to break concrete sleepers/pavement/brickwork into pieces. Weight : 30 kg (Approx) Man Power : Skilled : 01 Unskilled : 01

  33. MACHINES FOR WELDING OPERATIONS • Portable DC welding generator, • Double action weld trimmer for AT welding (Power pack version), • Rail profile weld grinder.

  34. Portable DC welding generator

  35. Portable D.C. Welding Generator Use: 1. It is a portable generator for producing DC current for the operation of arc welding equipment for reconditioning of points and crossings at site. 2. It has also an auxiliary AC unit for producing alternating current required for miscellaneous applications i.e. Lighting at worksite, operation of electrically driven devices like rail profile grinder, rail drilling, cutting machine etc.

  36. Portable D.C. Welding Generator Description: • I.C. Engine, • An alternator, • Control panel, • Tubular frame with 4 nylon wheels, • 2 double flanged wheels. Weight: Max 150 kg (Excluding transportation arrangement) Man Power: Skilled : 01 Unskilled : 01

  37. Double action weld trimmer for AT welding (power pack version)

  38. Double Action Weld Trimmer For AT Welding (Power Pack Version) Use: This machine is used for trimming the extra weld metal from rail (Top and sides) of AT welded rail joint after the welding operation. Components: • Trimming Unit, • Power Pack- a) Hydraulic pump, b) An engine. Man Power: Skilled: 01 Unskilled: 01

  39. Double Action Weld Trimmer For AT Welding (Power Pack Version) Salient features : • Prime mover : Petrol start kerosene/petrol run engine of minimum rating 3HP. • Hydraulic stroke : 120-150 mm • Minimum shearing force : 18 tonnes • Total weight : 175 Kg (Max.) • Life of shear blade : Trimming of minimum 200 joints • The machine is also provided with emergency hand pump device which can be used in case of failure of power pack for retrieving the trimming unit. • Tolerance before grinding : Top of rail head - + 0.5 mm to + 1.5 mm Side width of rail head- + 1.00 mm to + 2.0 mm

  40. Rail Profile Weld Grinder

  41. Rail Profile Weld Grinder Use: It is used for grinding of A.T. welded joints after weld trimming operation is complete. Components: 1. Grinding Unit, 2. An engine/electric motor, 3. Feed screw, 4. Frame. Man Power: Skilled : 01 Unskilled: 01

  42. Rail profile weld grinder Salient features : • Power pack : Generator or A.C. supply. • Weight including power pack: 80 Kg (Maximum) • Grinding tolerance : • 0.5 mm on top of rail head, gauge and non gauge faces with 1 metre straight edge. • 0.2 mm on top of rail head with 10 cm straight edge. • 0.3 mm on gauge and non gauge faces of rail head with 10 cm straight edge • Grinding time : 15 minutes (max.).

  43. Machines For Operation On Fittings • Heavy duty hydraulic extractor for jammed ERCs, • Toe load measuring device (Mechanical), • Toe load measuring device (Electronic).

  44. Heavy Duty Hydraulic Extractor For Jammed ERCs

  45. Heavy Duty Hydraulic Extractor For Jammed ERCs Use: It is used to remove jammed ERCs from concrete sleepers without any damage to sleeper. Components: 1. Feed rod/pin. 2. Hydraulic ram, 3. Pump, 4. Heavy and strong frame. Man power: Skilled : 01 Unskilled : 01

  46. Heavy Duty Hydraulic Extractor For Jammed ERCs • Salient Features: • Maximum weight : 40 Kg • Extraction force exerted on clip : 10 tonnes ( minimum) • Extraction stroke : 20 mm (min) • Time taken for removing jammed ERC including fixing & removing : 5-10 min.

  47. Toe Load Measuring Device Mechanical

  48. Toe Load Measuring Device Use: This machine is used to determine the toe load of elastic rail clips during service in the field. Components: 1. Pre calibrated helical spring, 2. Steel pointer, 3. Link hanger, 4. Rotating hanger, Toe Load -- Displacement of the pointer x Spring constant.

  49. Toe Load Measuring Device Salient Features: 1. Weight (Max.) - 12 kg 2. Capacity of the spring to measure the load - 1400 kg 3. Material of the main spring - Silico manganese spring steel conforming to Grade -55 of IS: 3195-1992 Man Power : 1 skilled.

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